Electrical devices having terminal interlocking means



Nov. 8, 1966 c. G. ANDERSON ETAL 3,284,605

ELECTRICAL DEVICES HAVING TERMINAL INTERLOCKING MEANS Filed Dec. 23,1964 80 as 3 1 86 T Inverrio n5 Carl G.Anders0rz Bradlee W. Williams 33Zlfaflua, Md \Dawn H'HtornegyS United States Patent Ofifice 3,284,605Patented Nov. 8, 1966 ELECTRICAL DEVICES HAVDIG TERMINAL INTERLOCKINGMEANS Carl G. Anderson, Elk Grove, and Bradlee W. Williams, Barrington,iilL, assignors to Comar Electric Company, Chicago, Ill., a corporationat Illinois Filed Dec. 23, 1964, Ser. No. 420,737 3 Claims. (Cl.2tlil166) This invention relates to electrical devices such aselectromagnetic relays or the like having terminal connections.

In electrical devices such as electromagnetically operated relays,terminal elements extend from beneath a base or header for connection toan electrical circuit. The terminal elements extend upwardly into theinterior of the device through apertures in the base. A familiar mannerof securing the terminal elements in the base is to cast in situ acylindrical plug of epoxy adhesive, glass or other insulating materialabout each of the terminal elements within the apertures in the basethereby bonding the terminal elements in their proper positions on thebase.

While such a manner of securing terminal elements has provedsatisfactory, difiiculty has been experienced in that the plugs formedof the cast adhesive or epoxy material have cracked with age or becomerelatively loose, permitting the terminal elements to rotate within thebase. Such difficulties are more likely to arise in relays wherein theterminal elements support contact elements which are subject to aturning or rotating torque, tending to loosen the terminal elements.Accordingly, an object of the present invention is improved and morereliable contact terminals and mountings which are mechanicallyinterlocked to the base to prevent relative turning of the terminalelements. A more specific object of the invention is a new and improvedmounting of terminal elements for relays to hold the terminal elementsagainst rotation relative to the base, particularly those terminalelements supporting contacts which result in a turning or twisting forcebeing applied to the terminal elements.

Many of the adhesives and epoxies used to secure the terminal elementsto the base are noxious and require a time consuming operation to locateand bond the terminal elements in their proper positions. Accordingly,another object of the present invention is a new and less expensivemanner of locating and securing the contact elements in position andholding the contact elements against turning movements relative to thebase.

A more specific object of the invention is to provide -cross arms on theterminal elements for insertion into locating slots formed on the baseso that the terminal elements are held by the cross arms against atwisting or turning movement. A still further object of the invention iscanting the cross arms at an angle to the slots so that the driving ofthe cross arms into the slots results in bending of the cross arms fromtheir free position to an interference fit of the cross arms within theslots, thereby preventing loosening of the contact elements relative tothe slots.

According to a specific object of the invention, an outer pin which ishollow and cylindrical extends beneath the base and has therein a bladeelement having cross arms fitted into slots formed on the base at theinterior side of the electrical device. Under this object of theinvention, the lower ends of the blade-like elements extend to the lowerends of the hollow cylindrical pins and are electrically andmechanically connected thereto by a solder connection formed by dippingth ends of the pin into a bath of solder. Also under this object of theinvention, the upper portions of the blades have secured theretogenerally U-shaped contact supporting arms on which are supported thecontacts movable by the armature of the electromagnetic relay.

Other and further objects of the present invention will be apparent fromthe following description and claims and are illustrated in theaccompanying drawing which, by way of illustration, shows preferredembodiments of the present invention and the principles thereof and whatis now considered to be the best mode contemplated for applying theseprinciples. Other embodiments of the invention embodying the same orequivalent principles may be used and structural changes may be made asdesired by those skilled in the art without departing from the presentinvention.

In the drawings:

FIG. 1 is an elevational view of a relay incorporating the terminalmounting means according to the preferred embodiment of the invention;

FIG. 2 is a side view of FIG. 1;

FIG. 3 is a view taken on the line 3-3 of FIG. 1 showing the contactsupporting elements;

FIG. 4 is a view of the base having the terminal receiving apertures andslots for receiving the cross arms of the blades;

FIG. 5 is a side view of a blade elementtaken along the line 55 of FIG.6 and in the direction of the arrows and showing'the canting of thecross arm relative to the plane of the blade;

FIG. 6 is an elevational view of one form of blade employed in the relayof FIG. 1;

FIG. 7 is an elevational view of another form of blade employed in therelay of FIG. 1

FIG. 8 is a plan View taken along the line 8-8 of FIG. 7 in thedirection of the arrows, and showing the twist of the upper bladeportion relative to the lower blade portion; and

FIG. 9 is a large sectional View of an aperture and slot in the base forreceiving a terminal element.

Referring now to the drawings, and more particularly to FIG. 1, there isillustrated an el ectrornagnetically operated relay 10 having aplurality of terminals or terminal ele ments 12 extending downwardlybeneath a base or header 14 for the relay 10. Normally, the relay isencapsulated with a cover attached to the top of the base 14 to protectthe interior of the relay including the coil 15, armature 16 andcontacts 18 operated by the armature 16. Preferably, the housing orcover (not shown) is hermetically sealed to the top of the base 14 toprevent contamination of the relay interior.

The relay 10 is employed herein for purposes of illustration, and it isto be understood that the present invention is also applicable to othertypes of electrical devices employing terminal elements which aresecured to an insulating base and which depend therefrom.

Heretofore, a common method of attaching a terminal to a base such asthe base 14 was to hold the terminal within one of the apertures 20,FIG. 4, and cast in situ thereabout a generally cylindrical plug ofadhesive, epoxy r plastic to bond the terminal 12 against verticalmovernent as well as rotati-ve movementrelative to the base 14. Sincemany of the materials employed to cast the terminal in situ are noxious,this mannerof securing the terminal elements has been relatively timeconsuming and expensive. Also, these cast plugs or connections to thebase have cracked with age, or have "become loosened, permitting turningof the terminal elements 12 in response to turning torques and forcesexerted thereon.

An important 'aspect of the present invention is the fact that theterminal elements are of a unique construction and are secured to thebase 14 in a novel manner which affords economy in constructing therelay, and improved reliability of operation by preventing thelikelihood of turning of the terminals relative to the base, especiallythose terminals which support contacts. More specifically, as seen inFIG. 4, the apertures 20 are provided with cross slots 21 which areadapted to receive cross arms 22 of blade-like elements 25, 26 or 27,FIGS. 1, 5, 6 and 7.

As best seen in FIG. 9, the aperture 20 extends completely through thebase 14 which is generally made of a phenolic plastic or otherinsulating material. The cross arm slots 21 extend downwardly for apredetermined depth which is approximately equal to the vertical heightof the cross arms 22 which are to be received in the cross slots 21.

The width of the cross arm slots 21 is slightly greater than thethickness of the metal from which the cross arms 22 are made. It ispreferred that the cross arms 22 be twisted relative to the verticalplane of the blade and that the cross arms 22 be jammed into the crossslots 21 so as to permanently deform, or alternatively, flex the crossarms 22 to obtain a wedge fit or tight fit of the arms 22 againstportions of the opposed side walls forming the cross slots 21.

The blades 25, 26 and 27 are made from a piece of relatively flat sheetmetal and the cross arms 22 are bent at an angle about a horizontal axisand relative to the flat blade of the body as best seen in FIG. Theblade 25 has its upper or contact support portion 30, FIG. 7, twistedabout a vertical axis for approximately 45, as best seen in FIG. 8, sothat when the blade is disposed in either of the two outermost apertures20A, the upper portion 30 is generally parallel to the armature actuator32, as best seen in FIG. 3. The upper portions 30 of the blade 25 haveapertures 34, FIG. 7, for receiving a rivet to secure generallyU-s-haped contact holders 35 and 36 in predetermined positions such thatcontact elements 37 and 38 on the outer or free ends of these U-shapedmembers are disposed in close and spaced relationship to the armatureactuator 32, FIG. 3. As can best be understood from FIG. 3, the contacts37 and 38 are disposed in close and spaced proximity to contacts 39 and40 formed on U-shaped contact holders 41 and 42 secured to the upperportions 44 of the blades 27, FIG. 1. The blades 27 are adapted to bereceived in the apertures 20C, FIG. 4, and the upper portions 44 do notrequire a twist therein because the cross slots 21 for the apertures 20Care generally parallel to the flat plane of the blade 27. The upperportions 44 of the blades 27 have apertures 45, FIG. 6, for receivingrivets whereby the contact holders 41 and 42, FIG. 1, are secured at theupper ends 44 of the blades 27. Preferably the upper portions 44, FIG.6, of the blades 27 are ofi-set relative to the lower tail portion 48which is in the aperture 20C. Thus, the upper portions 44 of blades 27are generally aligned with the upper portions 30 of the blades 25 andwith the contacts 37 and 41 and 38 and 40, as best seen in FIG. 3.

The blades 26, FIG. 1, are of the same general configuration as theblades 27, except that the blades 26 are shorter in that they aresevered along the line 50, shown in dotted line in FIG. 6. The blades 26have apertures 51 spaced downwardly of the apertures 45 for the blades27.

The blades 26 are inserted in the apertures 20B in the base and extendupwardly as best seen in FIG. 1, and have a contact surface 55, FIG. 1,secured by rivets through the apertures 51. The contact surfaces 55 arealigned for engagement with a contact 52, FIG. 1, depending beneath thecontact 40 on the contact holder 42. The contacts 52 and 55, FIG. 1, arenormally close-d to complete an electrical circuit between therespective blades 26 and 27. When the armature 16 is attracted by theelectromagnetic field and swings an attached actuator 32 leftwardly asseen in FIG. 1, the contacts 37, 39 and 38, 40 are made prior to themovement of the contacts 52 away from the contacts 55 to break theselower contacts. Thus, the relay employs the familiar make before breacontacts.

While the blades 25, 26 and 27, as hereinbefore described, arerelatively flat elements, it is to be understood that the presentinvention includes cylindrical or othershaped elements having cross armsatached thereto for fitting within locating slots formed in the base toorient the terminals in a predetermined position and to hold theterminals against the likelihood of rotation.

The terminals 12 of the relay 16 include the blades 25, 26 and 27 andhollow cylindrical pins 60 for the blades. The pins 60 are adapted to besecured by one or more tangs or like elements at the upper portion forengagement with the side walls of any of the apertures 20 and haveshoulders 61 formed on the underside of the base 14 in engagement with alower surface 63 of a circular flange 64 extending downwardly as aportion of the base 14. Thus, the tangs (not shown) prevent pulling ofthe sleeves downwardly and outwardly of the base 14 and the collar 61prevents pushing of the pins 60 upwardly through the apertures 20.

Preferably, the lower ends of the pins 65 are generally rounded tofacilitate insertion of the pin 60 into a socket. However, the verybottom tip 65 of the pin 60 is opened, i.e. apertured so that a reducedarea 66 of one of the blades 25, 26 or 27 can be inserted into theopening. It is preferred practice that the bottom-most end 68 of theblades extends just slightly outward throughout the opening at thebottom tip 65 of the pin 60. Thus, when the pin-s 60 are dipped into asolder bath, the solder is able to flow into the interior of the pins 60for a slight distance and to coat the low-er tips 68 of the blades 25,26 or 27 to electrically and mechanically connect the blades 26 to thepins 61). It is to be understood that the tail portion 48 of the blades25, 26 or 27 is slightly less in width than the inner diameter of thepins so that .a blade can be readily forced into the hollow interiorportion of the related pin, causing the reduced diameter 66 to extendoutwardly of the hollow pin 60 when a cross arm 22 limits the downwardmovement of the blade 25, 26 or 27 relative to the base 14. Thus, inassembling, the pins 611 are mechanically driven into the respectiveapertures 20A and 2GB and the blades 25, 26 and 27 are driven into therespective apertures 20A 26B and 20C to insert the cross arms 22 intotheir respective cross slots 21. Thereafter, the ends 65 of the pins 60are dipped in solder to afford a good electrical connection between theblades 25, 26 and 27 and their respective pins 60. At this point itshould be mentioned that the rearward two pins 60 depending downwardlyfrom the apertures 20D in the base receive wire connectors 70, FIG. 1,which extend upwardly to the base 72 on which is mounted the coil 15.The wires 70 are thus connected to the coil wire of the coil 15 and theends of the wire are connected by the solder to the pins 60.

The insulating base 72 is secured to an upstanding L- shaped bracket 74by a screw-type fastener 75. The L- shaped bracket 74 has a lower leg 76secured by screwtype fasteners 77 to the base 14. Disposed between theupper leg of the U-s'haped bracket 74 and the coil 15 is a downwardlyextending leg 78 of a U-shaped member '79 which is also secured to theupstanding leg of the bracket 74 by the pin 75. The U-shaped member 79serves as the armature support member for the armature 16 which ispivotally mounted thereon and which is biased by a spring 80 to engagethe top of the actuator blade 32 with the armature stop log 82 dependingdownwardly from a downward leg 83 of the U-shaped member 79. The spring80 for biasing the armature 16 to its return position shown in FIG. 1 isconnected to a spring hanger 86 struck upwardly and rearwardly from theU- shaped member 79 to form a hook. The opposite end of the spring 80 issecured about a tab 88 formed at the top of the armature 16.

An opening 90, FIG. 2, is formed on the U-shaped bracket at the bendforming the downwardly turned leg 83 and the upper portion of thearmature 16 is inserted therethrough to extend upwardly above the topsurface of the U-shaped member 79 as seen in FIGS. 1 and 2. Preferably,the armature 16 is provided with notched shoulders 92, FIG. 2, beforebeing disposed for pivotal mounting on portions 93 of the U-shapedmember 79.

For the purpose of preventing the armature 16 from moving rightwardly asseen in FIG. 1, and moving off the supports 93 from the slottedshoulders 92, an armature retaining member 94 is secured by a pair ofscrews 95 to the depending leg 83 of the U-shaped member 79. Thearmature retaining blade 94 has at the top surface thereof a centrallyand rearwardly extending bent portion 96 which is disposed in closeproximity of the armature 16 but spaced therefrom. The bent portion 96prevents the forward or rightward movement of the armature to removenotched shoulders 92 from the supporting blade portion 93 of theU-shaped member 79. In this manner, the armature 16 is retained in itsposition until attracted against the pole piece 98, whereupon the lowerportion of the armature 16 pivots in a clockwise direction as seen inFIG. 1 to move the contacts 37 and 38 to make contact wtih the contacts39 and 40 prior to flexing the contact supports 41 and 42 to separatethe lower contacts 52 from the lower contacts 55 supported by the blades26.

From the foregoing, it will be seen that the present invention residesin a new and novel manner of mounting a terminal to a base and affordsimproved reliability in providing cross arms 22 to prevent twisting ofthe terminal relative to the base. Furthermore, the cross arms 22 serveto locate the contacts secured thereto in a predetermined positionfacilitating construction of the relay.

Hence, while we have illustrated and described preferred embodiments ofmy invention, it is to be understood that these are capable of variationand modification.

We claim:

1. In an electrical device presenting a terminal adapted to be disposedin an upright position, an insulating base formed with an aperture intowhich one portion of a terminal element is entered to be disposedgenerally in a vertical plane when in an upright position, a cross slotin the base presenting side walls within the base which communicate withsaid aperture, and said terminal element having a generally horizontalflexible cross arm in said slot, said cross arm extending laterally fromsaid portion of said terminal element and normally canted at an angleout of said vertical plane and relative to the plane of said slotwhereby the cross arm in said slot is bent from its normal positionproducing a wedge fit between said cross arm and said slot tomechanically interlock the terminal element with said base without theneed for an adhesive.

2. An electrical device according to claim 1 wherein said terminalelement has a lower portion extending beyond the aperture in said base,a hollow terminal pin fitted over the lower portion of the terminalelement, the pin having an open lower end exposing the lower end of theterminal element enabling soldering of the lower end of the pin to thelower end of the terminal element.

3. An electrical device according to claim 2 wherein the electricaldevice is a relay having an. armature, said terminal element having anupper portion and an electrical contact thereon located adjacent saidarmature to be actuated by the armature upon energization of the relay.

References Cited by the Examiner UNITED STATES PATENTS 2,457,520 12/1948Benander 339220 2,523,001 9/1950 Lamater 339-221 3,175,066 3/1965Fiddler ZOO-166.1 X

ROBERT K. SCHAEFER, Primary Examiner.

H. O. I ONES, Assistant Examiner.

1. IN AN ELECTRICAL DEVICE PRESENTING A TERMINAL ADAPTED TO BE DISPOSEDIN AN UPRIGHT POSITION, AN INSULATING BASE FORMED WITH AN APERTURE INTOWHICH ONE PORTION OF A TERMINAL ELEMENT IS ENTERED TO BE DISPOSEDGENERALLY IN A VERTICAL PLANE WHEN IN AN UPRIGHT POSITION, A CROSS SLOTIN THE BASE PRESENTING SIDE WALLS WITHIN THE BASE WHICH COMMUNICATE WITHSAID APERTURE, AND SAID TERMINAL ELEMENT HAVING A GENERALLY HORIZONTALFLEXIBLE CROSS ARM IN SAID SLOT, SAID CROSS ARM EXTENDING LATERALLY FROMSAID PORTION OF SAID TERMINAL ELEMENT AND NORMALLY CANTED AT AN ANGLEOUT OF SAID VERTICAL PLANE AND RELATIVE TO THE PLANE OF SAID SLOTWHEREBY THE CROSS ARM IN SAID SLOT IS BENT FROM ITS NORMAL POSITIONPRODUCING A WEDGE FIT BETWEEN SAID CROSS ARM AND SAID SLOT TOMECHANICALLY INTERLOCK THE TERMINAL ELEMENT WITH SAID BASE WITHOUT THENEED FOR AN ADHESIVE.